Method and means for making a carbon pattern on a flexible printing plate

ABSTRACT

A pattern formed by heat transferable duplicating substances disposed in a predetermined array on a flexible sheet is transferred by application of heat to a flexible plate mounted on a cylindrical drum. The flexible plate is prestretched on the drum. The plate can then be removed from the drum and mounted on a cylinder of a rotary press for printing pattern carbon sheets. Apparatus including the cylindrical drum and means for applying heat thereto while the drum rotates to effect transfer of the pattern is described.

United States Patent Johnson Mar. 7, 1972 [54] METHOD AND MEANS FOR MAKING A CARBON PATTERN ON A FLEXIBLE PRINTING PLATE [72] lnventor: Billie J. Johnson, 702 Fairhope Ave, Fairhope, Ala. 36532 [22] Filed: July 7, 1969 21 Appl. No.: 839,613

[52] U.S.Cl. ..l0l/33,l01/401.1 [51] Int. Cl ..B41d 7/00, B41c 3/04 [58] Fieldofsearch ..l01/33,34,401.1; [17/36.]

[56] References Cited UNITED STATES PATENTS 1,449,979 3/1923 Freedman 10l/401.1 282,111 7/1883 Osborne ..l0l/33 908,268 12/1908 Jacobson .....101/34 1,906,572 5/1933 Girdwoyn ..101/33 1,911,592 5/1933 Supligeau et al.. ..1 17/361 1,983,948 12/1934 Rutkoskie 1 17/36.1 X 2,074,218 3/1937 Fi'iess 101/34 2,506,427 5/1950 MacKay 101/33 3,392,041 7/1968 Crow et a1. ..l17/36.1

Primary Examiner-Robert E. Pulfrcy Assistant Examiner-E. M. Coven Attorney-Polachek, Saulsbury & Hough [57] ABSTRACT A pattern formed by heat transferable duplicating substances disposed in a predetermined array on a flexible sheet is transferred by application of heat to a flexible plate mounted on a cylindrical drum. The flexible plate is prestretched on the drum. The plate can then be removed from the drum and mounted on a cylinder of a rotary press for printing pattern carbon sheets. Apparatus including the cylindrical drum and means for applying heat thereto while the drum rotates to effect transfer of the pattern is described.

5 Claims, 10 Drawing Figures METHOD AND MEANS FOR MAKING A CARBON PATTERN ON A FLEXIBLE PRINTING PLATE This invention concerns a process and apparatus by means of which a carbon pattern can be made on a carbon-printing plate, and more particularly concerns a method and means for making plates used in printing carbon or other duplicating substances in specified areas on sheets of paper. Paper sheets printed in this way are generally referred to as pattern carbons.

A pattern carbon is a paper sheet which has carbon or other pressure sensitive marking substance disposed in predetermined areas on the rear side of the sheet. On the front side of the sheet is a printed form. When onewrites on the printed form, only those portions of the written material backed up by duplicating carbon on the back of the sheet transfer to an underlying paper sheet. Before a printer prints forms on the front sides of the sheets it is necessary to apply the duplicating carbon to the backs of the sheets to be printed. This work is generally done by a carbon paper manufacturer who employed special equipment for the purpose.

Heretofore, the following procedure was generally employed in making a plate used in printing pattern carbons. A printer would first determine from his customer what areas on the back of the sheet to be printed were to be carbonized. He would then draw a pattern of the carbon areas on a sheet of paper and would send it to a carbon paper manufacturer. The carbon paper manufacturer would duplicate the pattern on a flexible printing plate used in printing the carbon paper. The carbon paper would be printed on a rotary press so that the plate had to fit properly around the rotary cylinder in the press. Heretofore, the carbon manufacturer would duplicate on a flexible flat rubber or plastic plate the pattern specified by the printer. Then this flexible plate would be wrapped around the cylinder. If the printers pattern were drawn on the flexible plate to the same dimensions as specified by the printer, the pattern would be too long in the direction of the circumference of the cylinder when the plate was bent around the cylinder. It was therefore necessary heretofore for the carbon paper manufacturer to calculate how much the pattern would stretch when the flexible plate was bent around the cylinder and to reduce the pattern in size by this amount. The procedure for calculating the stretch and required compensating reduction is quite complex and is made more difficult when the pattern is complicated in form rather than wholly rectangular or of some simple form. Costly errors were frequently made in performing the calculations. After much trial and error the final proper reduction of the pattern was determined and the reduced pattern was then drawn by hand on the flexible rubber or plastic printing plate. Undesired areas of the plate were then cut out leaving the pattern as holes in the flexible plate. Then the flexible plate would be placed on the cylinder of the rotary press for making the pattern carbons ordered by the printer.

The present invention is directed at enabling a carbon manufacturer to make pattern carbon paper more quickly, efficiently and economically by saving many hours of labor heretofore required in calculating and redrawing carbon patterns, by eliminating the errors involved in drawing and redrawing reduced carbon patterns, and by eliminating the laborious trial and error involved in producing properly reduced patterns on carbon-printing plates.

According to the invention, a paper pattern sheet on which a desired pattern is being drawn is backed up by a sheet of carbon paper. The pattern is thus duplicated in carbon on the back of the pattern sheet. The pattern sheet is then transferred to a first cylinder, drum or roller of the same diameter as one in a rotary printing press used for printing pattern carbons. Around the first cylinder is mounted a flexible rubber or plastic plate. The pattern sheet is mounted tightly around the flexible plate with the carbon pattern facing the flexible plate. The first cylinder is then rotated in contact with a heated rotating second cylinder. Alternatively the first cylinder is rotated while it rolls over a heated flat bed plate. The carbon pattern then transfers to the flexible plate. The pattern sheet can then be removed from the flexible plate. Unwanted areas are then cut out of the flexible plate while it is still on the first cylinder. The flexible plate can now be removed from the first cylinder and mounted on the cylinder of the rotary press for printing pattern carbons.

The invention will be explained in further detail in connection with the drawings, wherein:

FIG. I is a plan view of a pattern sheet and carbon paper sheet used in performing the process of making a pattern carbon-printing plate according to the invention.

FIG. 2 is a plan view of a flexible plate used in making a pattern carbon-printing plate.

FIG. 3 is a sectional view taken on line 3-3 of FIG. 2.

FIG. 4 is a front view of a machine employed for making a pattern carbon printing plate.

FIG. 5 is an end view taken on line 55 of FIG. 4.

FIG. 6 is a cross-sectional view taken on line 6-6 of FIG. 4.

FIG. 7 is a flow diagram of the process according to the invention.

FIG. 8 is a side view, with parts broken away or in section, of another machine used in making a pattern carbon-printing plate.

FIG. 9 is a top plan view of the machine of FIG. 8, parts being broken away.

FIG. 10 is an enlarged fragmentary sectional view taken on line l0-10 of FIG. 9, through a rotatable cylinder of the machine.

Referring first to FIG. 1, there is shown a rectangular paper sheet 10 on which has been drawn a generally rectangular pattern 12. One corner portion 14 of the pattern and an L-shaped end and side portion 16 have been left clear. One corner I8 of the sheet has been turned up to show the rear of the sheet. Sheet 10 is applied to a carbon sheet 20. This carbon sheet is coated with a pressure sensitive and heat sensitive transferable dark colored substance 22. This substance has transferred to the back of sheet 10. Carbon area 12 on the back of sheet 10 registers with pattern 12 on the front of the sheet. Clear area 16' registers with clear area 16. Excess end portions 21 of sheet 10 extend beyond dotted lines 25 which define the limits of the pattern 12 on the sheet. These end portions are employed in mounting sheet 10 on a flexible printing plate described below.

FIGS. 2 and 3 show a carbon-printing plate 30. This plate includes a flexible metal base or backing 32 which may be formed with end flanges 34. Bonded to the upper side of backing 32 is a flexible rubber or plastic pad 36. This pad has cutout portions 14a and I6acorresponding to clear or unmarked portions 14,l6 of sheet 10 and the registering corresponding carbon pattern portions on the back of sheet 10. Plate 30 is ready to be mounted around a cylinder in a rotary printing press for printing carbon sheets bearing precisely the pattern 12 inscribed on sheet 10. Cutout portions 14a and will leave clear unprinted areas on the carbon sheets.

FIGS. 4, 5 and 6 show one assembly of apparatus 50 which can be used in producing plate 30. Apparatus 50 includes a frame 52 on which is a cylinder or drum 54 rotatably carried by shaft 56. The cylinder is driven by a variable speed motor 58 via a belt 60 engaged with drive wheel 61 on shaft 56. A lateral axially extending groove 62 is formed in cylinder 54. In this groove engages flanges 34 of plate backing 32. End portions 21 of sheet 10 fit into groove 62 between abutted flanges 34; see FIG. 6.

Axially parallel to cylinder 54 is another cylinder 66. This cylinder is rotatably supported on a shaft 68. The cylinder is electrically heated by heating elements 69 connected to wires 70 terminating at slip ring 71. A foot operated switch 72 is connected in circuit with motor 58, wires 77, wipers 79, wires 70 and heating elements 69. Shaft 68 is supported on a frame 73 pivotally supported by pins 74 to frame 52. Springs 76 connected between the frames 52 and 73 urge cylinder 66 against cylinder 54 so that both cylinders rotate simultaneously in opposite directions with cylinder 54 driving cylinder 66.

In order to retract cylinder 66 away from cylinder 54 there is provided a handle bar 78 at the front of the frame connected to slidable bars 80. The bars 80 extend horizontally rearwardly to links 82 pivotally engaged with bars 80 and supported on stationary arms 83 extending rearwardly. Links 82 contact forwardly extending fingers 85 on frame 73. When the handle bar is pulled forwardly cylinder 66 is retracted rearwardly from cylinder 54 as clearly shown in FIG. 5, while springs 76 are stretched. When the handle bar is released the springs will draw the-frame forwardly so that cylinder 66 rotatably contacts cylinder 54.

In the plate forming process, pattern 12 is first drawn or inscribed on the front of sheet while carbon sheet faces the back of sheet 10 as shown in FIG. 1. This is indicated as step I in FIG. 7. A plate 30 is mounted on cylinder 54 by bending the plate around the cylinder and engaging its flanges 34 in groove 62. This is indicated as step II in FIG. 7. If desired other ways of removably mounting the plate on the cylinder can be employed. In step III, sheet 10 is secured around plate 30 on cylinder 54 with ends 21 engaged in groove 62. Other ways of mounting sheet 10 on plate 30 can be employed if desired. In any case, carbon pattern 12' faces the outer surface of the flexible pad 36. In step IV, cylinder 66 is applied to cylinder 54 and the motor is started by pressing foot switch 72 while cylinder 66 is heated electrically. The heat of cylinder 66 causes carbon pattern 12' to transfer to the outer surface of pad 36. In step V, sheet 10 is removed from plate 30 and unwanted areas of the pattern are cut out of pad 36. This leaves the pad with cutout portions l4a,16a shown in FIGS. 2 and 3. The plate can now be removed from cylinder 66 and transferred to a cylinder of the same diameter in a rotary printing press to print carbon sheets bearing the desired pattern with clear areas as specified.

It will be noted that no calculations of stretch in pattern dimensions are required since flexible plate 30 is prestretched on cylinder 54 before the pattern sheet 10 is applied. Cutouts of pad 36 are performed on plate 30 while it remains on cylinder 54 so no reduction dimensions have to be calculated. Trial and error in obtaining the correct pattern dimensions on the flexible printing plate are omitted. Much labor and material heretofore wasted are now conserved.

FIGS. 8, 9 and 10 show another machine 100 which can also be used to produce plates 30 ready for printing pattern carbons. In machine 100 frame 102 supports a horizontal plat form 104 on which is mounted a flat plate heater 106. In the heater are electric heater wires 108. The wires are connected to a cable 110 in series with a rheostat 112 and plug 114. The rheostat has a control handle 116 for adjusting its resistance. The plug is to be inserted into a suitable power source for heating the bed plate. Disposed alongside the heater for almost the full length of the frame is a pair of rack gears 118 mounted by screws 119 on sidewalls 120 of the frame. End walls 122 of the frame extend upwardly above platform 104 and serve as stops for a rotatable cylinder 54a. The cylinder has end walls 124 extending radially beyond the cylinder to move in channels 121 between heater 106 and sidewalls 120. Secured by screws 123 to outer sides of end walls 124 are spur gears 126 which ride on rack gears 118 respectively. A handle 128 at one end of the cylinder is used to turn the cylinder to advance it over the heater plate 106. A groove 62a is provided in cylinder 54a to receive end flanges 34 of the plate and end portions 21 of sheet 10. A shim or wedge 130 can be inserted in groove 620 between ends 21 of the sheet to secure the sheet and flexible plate to the cylinder. A hole 132 in the cylinder reached through a hole 134 in one end wall 124 admits a tool to force shim 130 out of groove 620 when the sheet is to be removed from the cylinder. The shim can be wedge shaped if desired to hold the strip and flexible plate more tightly to the cylinder.

Sheet 10 bearing. pattern 12 and carbon pattern 12' as shown in FIG. 1 is mounted on plate 30 which is bent and secured around the cylinder. The heater elements 108 are energized and c linder 54a is manually rotated as it advances over the heate plate 106. The carbon pattern transfers to sheet 10. Then the cylinder is turned back to starting position shown in FIGS. 8 and 9. Sheet 10 is removed. Portions 14a and 16a indicated in FIG. 2 are cut out of pad 36 while plate 30 is still on cylinder 54a. Then the plate can be removed and transferred to the cylinder of a rotary printing press. The procedure including steps I-V outlined in FIG. 7 apply equally well to the process performed by machines 50 and 100.

While a certain specific pattern is indicated in FIGS. 1,. 2 and 3 it will be understood that any desired pattern can be inscribed on sheet 10 and formed in pad 36 of plate 30. Also other apparatus can be used in performing the process than specifically shown in FIGS. 46 and 8-10.

What is claimed is:

1. Apparatus for making a flexible rectangular printing plate mountable in a rotary cylinder printing press, comprising a cylinder; a flexible rectangular plate; means for removably mounting the plate around said cylinder, said plate comprising a thin flexible backing, and a flexible pad bonded to the backing to receive a transferable pattern, said flexible pad being cuttable for removal of selected parts thereof leaving the remainder of the pad bonded to the backing for.subsequent use in printing said pattern in said pr'ess'when the plate is mounted in said press; means for engaging a sheet having a heat transferable pattern thereon on said cylinder and around the plate with the pattern in contact with the plate; a heater; and motor means operatively connected to the cylinder for rotating the same while in contact with the heater to transfer said pattern to said pad; and said means for mounting the plate on the cylinder comprising a groove in one side of the cylinder, said plate having end flanges engageable in said groove.

2. Apparatus as defined by claim 1, wherein the heater is another cylinder rotatably supported and axially parallel to the first cylinder, said other cylinder containing electrical heater elements.

3. Apparatus as defined by claim 1, wherein the heater is a flat horizontal member containing electrical heater elements; a frame supporting the flat heater; and horizontal guide means for supporting the cylinder while it is rotated over the heater.

4. Apparatus as defined by claim 3, wherein said guide means comprises rack gears supported by said frame, and spur gears carried by the cylinder and engaged with the rack gears.

5. Apparatus as defined by claim 1, wherein the heater is a flat horizontal member containing electrical heater elements; a frame supporting the flat heater; and horizontal guide means for supporting the cylinder while it is rotated over the heater; said means for rotating the cylinder comprising a handle secured to one end of the cylinder. 

2. Apparatus as defined by claim 1, wherein the heater is another cylinder rotatably supported and axially pArallel to the first cylinder, said other cylinder containing electrical heater elements.
 3. Apparatus as defined by claim 1, wherein the heater is a flat horizontal member containing electrical heater elements; a frame supporting the flat heater; and horizontal guide means for supporting the cylinder while it is rotated over the heater.
 4. Apparatus as defined by claim 3, wherein said guide means comprises rack gears supported by said frame, and spur gears carried by the cylinder and engaged with the rack gears.
 5. Apparatus as defined by claim 1, wherein the heater is a flat horizontal member containing electrical heater elements; a frame supporting the flat heater; and horizontal guide means for supporting the cylinder while it is rotated over the heater; said means for rotating the cylinder comprising a handle secured to one end of the cylinder. 